Facade Covering Panel Member

ABSTRACT

A panel member prepared from a fibrous slurry and replicates a structure prepared from masonry, carpentry, or other finishes. The panel member includes a body, a plurality of ornamental sections, a plurality of interior filler sections, and an exterior filler section. The body is prepared from a substantial uniform caliper of fiber material. The exterior filler section thickness is substantially equal to a thickness of the interior filler sections.

FIELD OF INVENTION

This invention relates to a facade covering panel member and in particular to a wall covering panel made of molded fiber material.

BACKGROUND

The practice of covering an interior wall or an exterior wall for aesthetic purposes (i.e. stone, brick, wood panels, tile, etc.) has traditionally involved standard masonry, carpentry, or finishing practices, where a stone mason, carpenter, or other finisher arranges stones, bricks, wood panels, tile or other decorative features onto the wall and sets them in place using mortar, paste, adhesive or nails. The process of arranging and adhering this facade, which may include random shapes and sizes, is tedious and requires substantial skill. As a result, attempts have been made to simulate such a trade using less expensive materials and less labor-intensive methods. One such attempt involves constructing a wall from concrete. The concrete may be molded to the shape of stone, bricks, tile, wood panels or other decorative feature. Another such example includes manually texturing the concrete before it cures. One problem with using concrete is that concrete tends to have a substantially smooth texture, unlike natural stone or brick. Another disadvantage with such concrete walls is that solid concrete is also extremely heavy.

In other attempts, wall facades have been manufactured from synthetic resins, such as a plastic, fiberglass, or styrene foams, which are formed to conform with the outer shape of the products to provide an appearance of masonry, carpentry, or other finishes. While plastic and styrene resin foams are light in weight and inexpensive to manufacture, their use is an environmental concern because they are not perishable and do not naturally decompose in landfills. Furthermore, these plastic facades are generally bulking and brittle.

One alternative material to plastics, which has been found to be suitable for use in packing or cushioning material, is a molding prepared from a mixture of water and paper, form a fibrous pulp slurry. The fibrous pulp slurry can be molded into finished articles having a plurality of contoured shapes. Such molded member are relatively inexpensive to produce in large quantities, are biodegradable, and are easy to work with. Accordingly, the use of such molding processes for faux facades is highly desirable.

Molded members formed from a fibrous slurry, such as a pulp slurry, are typically produced by the process of matting the slurry fibers onto one side of a forming die by first inserting the die into the slurry. A vacuum is then applied in such a manner that the water held in the slurry passes through a screen having perforations and through channels in the die. As a result a layer of wet fibers deposited on the die surface is left, and after sufficient water has been drawn to obtain the required thickness of the fiber layer, the die is removed from the slurry. The formed molded article can then be removed from the forming die, and then the molded member can be dried for further finishing and packaging.

One problem associated with producing large molded articles from a fibrous slurry, such as a wall covering panel member, is the need to prevent warping that may prevent the panel member from being a realistic.

SUMMARY

The present invention has been devised to solve the technical problems described above, and an object of the present invention, among others, is to provide a large wall covering panel made of a thin layer of fibrous slurry that does not warp when assembled onto a wall surface. The panel member includes a body, a plurality of ornamental sections, a plurality of interior filler sections, and an exterior filler section. The body is prepared from a substantial uniform caliper of fiber material. The exterior filler section thickness is substantially equal to a thickness of the interior filler sections.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example with reference to the accompanying figures of which:

FIG. 1 is a close-up perspective view of a panel member according to the invention;

FIG. 2 is a close-up perspective view of the panel member in FIG. 1, showing a rear surface;

FIG. 3 is a front view of connecting panel members according to the invention, showing interlocking joints between the panel members;

FIG. 4 is a sectional view of the connecting panel members, along the 5-5 line;

FIG. 5 is a close-up perspective view of another panel member according to the invention;

FIG. 6 is a front view of connecting panel members according to FIG. 5, showing interlocking sections between the panel members;

FIG. 7 is a perspective view of a mold used to prepare a panel member according to the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to FIGS. 1-4, a panel member 1 according to the invention is shown, having a body 10, a plurality of ornamental sections 12, a plurality of interior filler sections 14, an exterior filler section 16, and flashing 18 extending from the exterior filler section 16.

The panel member 1 is prepared from a uniform layer of fiber material, which may be paper or other fibrous material. In fact, there are numerous organic and inorganic materials, in fiber form, that may be used instead of or included with paper fibers in a fiber material for the panel member. In one embodiment, the fiber material is originally a pulp slurry using pre- and post-consumer newsprint, kraft paper and other selected waste papers which are fed into a pulping machine and mixed with water. The recycled paper is reduced to small pieces and then further defibered into a homogenized slurry of paper and water. During defibering, dry pulp sheets or paper are added with water and continuously agitated such that the dry pulp sheets or clean recycle paper sheets are broken down and separated into fibers, that is, to separate all of the fibers. Other additives may also combined with the slurry, including sizing agents (i.e. waxes) and binders to ensure proper binding of all the additives. It is also possible to use other fibrous materials. However, using 100% pre- and post-consumer newsprint, kraft paper and other selected waste papers, the panel member 1 remains economical and environmentally friendly. As a result, the panel members 1 are lightweight and quite manageable; the panel member 1 may be recycled in a convenient manner.

The panel member 1 may be provided in various shapes, sizes and thicknesses. In the embodiment shown, the panel member 1 is substantially 4′-½″ long and 5′-10″ wide. As a result, the panel member 1 should be thick enough so the panel member 1 can be easily manageable for installation onto a wall or ceiling. Furthermore, the thickness will affect any warping once the panel member 1 is installed. Accordingly, the panel member 1, as shown, includes a nominal caliper of ¼″.

The body 10 is formed from a dried slurry, and includes an upper surface 10 a that is smooth and a lower surface 10 b that is left naturally rough. This shape and roughness is dependent and results from the molding process, which is described in more detail below. The thickness of the upper and lower surfaces 10 a, 10 b are controlled by the molding process. However, depending on the shape of the ornamental sections 12, which depends on the type of brick, rock, wood, or other façade surfaces being replicated, the body 10 may have more or less relief, which provides better replication of masonry, carpentry, or other finishes.

As shown in FIG. 1, the ornamental sections 12 extend outward from the interior and exterior filler sections 14, 16 and are formed in the shape of blocks, stone, wood panels, or other decorative features. This provides an appearance that the ornamental sections 12 are separate and/or bound together by connecting seams (i.e. mortar, grout, or other known seams), which is replicated by the interior and exterior filler sections 14, 16. In the alternative, the interior and exterior filler sections 14, 16 may be positioned between the ornamental sections 12 such that replicate an appearance is prepared wherein the ornamental sections 12 seem bound together through a seamless connection (i.e. floating floor tiles, tin panels, etc.).

In FIGS. 1-4, the panel member 1 has ornamental sections 12 shaped as bricks, while the interior and exterior filler sections 14, 16 are shaped and dimensions to replicate brick mortar, having a straight lines and uniform dimensions (i.e. uniform grid pattern). Other materials, which are commonly used in building structures and having ornamental features, may be replicated, including granite, travertine, limestone, concrete block, glass block, stucco, tile, metal panels, or even timber. In other embodiments, the interior and exterior filler sections 14, 16 are formed to replicate grout, paste, concrete grout, or other spacing features known between the ornamental sections 12. As discussed above, in the alternative, the interior and exterior filler sections 14, 16 may replicate the appearance of a seamless connection (i.e. floating floor tiles, tin panels, etc.).

While the ornamental sections 12 are generally symmetrical in the embodiment shown, the ornamental sections 12 may be arranged in different shapes. For instance, the ornamental sections 12 may replicate bricks laid in a variety of ‘bonds’ or patterns of headers and stretchers on a series of courses, tile, or wood panels pieced together in a specific pattern. It is also possible that the ornamentals sections are molded like ceramic tile with grout there between. The ornamental sections 12 may be shaped differently. In FIGS. 5 and 6, the ornamental sections 12 are shaped like rock sections of a stone wall, having irregularity in shape, surface relief, and texture. The interior and exterior filler sections 14, 16 are more irregular in shape than the interior and exterior filler sections 14, 16 in FIGS. 1-4, and replicate a mortar mix and design commonly used in the stone wall masonry.

With reference back to FIG. 2, the ornamental sections 12 are hollow, and a cavity 20 is formed along the lower surface 10 b of the body 10 and between the interior and exterior filler sections 14, 16. This allows the panel member 1 overall weight to be reduced, which makes the panel member 1 more manageable to install. However, since the overall weight of panel member 1 is reduced, the panel member 1 becomes more susceptible to becoming warped that provides a poor appearance of replication. As a result, the filler sections 14, 16 are structured and dimensioned to provide support to the panel member 1 and minimize warping. As discussed, the interior and exterior filler sections 14, 16 are formed to replicate grout, paste, concrete, or spacing between the ornamental sections 12.

In the embodiment shown, the interior filler sections 14 and the exterior filler sections 16 are generally the same thickness. However, according to the invention, the thickness of the exterior filler sections 16 cannot be larger than the thickness Tg of the interior filler sections 14. If the exterior grout lines 16 are thicker, then the panel member 1 warps. Additionally, the thickness of the exterior filler sections 16 cannot be smaller than the thickness Tg of the interior filler sections 14. If the exterior grout lines 16 is substantially smaller, then the panel member 1 warps also. An interior section of the body 10 either bows in or out depending on this design and variation, which provides a poor appearance and the panel member does not look like a wall prepared from masonry. As shown in FIG. 4, the interior filler section thickness T_(g) is substantially equal to the ornamental section thickness T_(o), which results from the ornamentals sections 12 being hollow and the molding process as further detailed below. The body thickness Tb is measured from the upper surface 10 a to the lower surface 10 b, and is equal to the interior filler section thickness T_(g) and the ornamental section thickness T_(o), since the flashing 18 is an extension from the exterior filler section 16 and directed parallel to the upper and lower surfaces 10 a, 10 b of the body 10.

Generally, flash is formed during the molding process, which is excess material attached to a molded, forged, or cast product, which must usually be removed. This is typically caused by leakage of the material between the two surfaces of a mold or between the base material and the mold.

While the exterior filler section 16 thickness is substantially equal to a thickness of the interior filler sections 14, the exterior filler section 16 width W_(e) is less than the interior filler sections 14 with W_(i). As shown in FIG. 4, since the flashing 18 is directed away from the exterior filler section 16, connection between adjacent panel members 1 may be hindered or forcibly limited by the width of the flashing 18 and exterior filler section 16. Accordingly, the exterior filler section 16 width W_(e) is limited to substantially half that of the interior filler section 14 width W. However, it is possible that other dimensions are possible, as long as the exterior filler section 16 width W_(e) is less than that of the interior filler section 14 width W_(i).

When molding the panel member 1 from a fibrous slurry, flash will develop, like most molding processes. In most instances, where one mold is used, a flashing is generally directed perpendicular with respect to the to the upper and lower surfaces 10 a, 10 b of the body 10. This creates an uneven installation surface against a wall, ceiling, or other structure, because the flashing is not uniform and does not allow the panel member 1 to lay flat.

The process of removing flash, known as deflashing, is commonly performed via cutting, breaking, grinding, or tumbling. Some foundries use robot autogrinders to remove this unwanted material. However, removal of the flashing requires additional steps which are cumbersome, time consuming, and expensive. In the embodiment shown and according to the invention, the flashing 18 is directed parallel to a planar upper surface 10 a of the body 10. The flashing 18 does not affect the warping because the flashing 18 is directed away from the body 10 and is small enough to impede connection between the adjacent panel members 1, considering that the exterior filler section 16 width W_(e) is less than that of the interior filler section 14 width W_(i).

With reference to FIGS. 3 and 4, panel members 1 are shown connecting to each other.

For each panel member 1, opposing sides (not top or lower surfaces 10 a, 10 b) have either a first connection section A or a second connection section B. The first connection section A is keyed to connection section B, and vice versa. Accordingly, when the first connection section A of one panel member is positioned adjacent to a second connection section B of another panel member 1, then the first and second connection sections A, B come together, and compliment a connection between the connecting panel members 1.

As shown, the first and second connection sections A, B include finger joints 30, which are complementary rectangular protrusions 32 and cuts outs 34, which interlock finger joints 30 in an adjacent panel member 1. Again, since the flashing 18 is directed parallel to a planar upper surface 10 a of the body 10 and minimized, and the exterior filler section 16 width W_(e) is less than that of the interior filler section 14 width W_(i), the first and second connection sections A, B of adjacent panel members 1 can be performed, and provide a realistic look of a structure prepared from masonry, carpentry, or other finishes.

With respect to FIGS. 5 and 6, another embodiment of the invention is shown, wherein the panel member 1 includes body 10, a plurality of ornamental sections 12, a plurality of interior filler sections 14, an exterior filler section 16, and flashing 18 extending from the exterior filler section 16, but the first and second connection sections A, B are profiled differently than the embodiment shown in the FIGS. 1-4. In fact, the first and second connection sections A, B may be a keyed profile side, that match a corresponding first and second connection section A, B from an adjacent panel member 1 when positioned next to each other. There are no finger joints 30.

For panel members 1, which have a more grid pattern, it is possible to only have two connection sections A, B, on opposing sides of the panel member. However, as shown in FIGS. 5 and 6, the panel member may have first and second connection sections A, B positioned on all sides of the body 10. As a result, a panel member 1 that replicates a stone wall, for instance, could match with adjacent panel members 1 in different ways, creating a less uniform and consistent look.

Referring now to FIG. 7, the apparatus for molding panel members 1 from a fibrous slurry, generally designated 100, of the subject invention is shown comprising a die 110 having molding screen 112, and a vacuum mechanism 130 for drawing slurry into the die 102 and further extracting water away from the slurry.

The die 110 may be formed from any material having the characteristics of being water-insoluble and porous. The material must also be sufficiently rigid to withstand the required vacuum pressures and easily shaped to permit the molding surfaces of the die 110, contrary to the accepted practice, to be constructed either by hand using simple hand-held cutting tools, or by machine using relatively simple manual tools, or automatically using computer controlled cutting tools. Such materials include, but are not limited to, phenol-formaldehyde resin foams, polyurethane resin foams, and urea-formaldehyde resin foams; ceramics; foam metals; and other similar materials. Accordingly, the die 110 of the invention may be manufactured with significantly less time and cost than conventional forming dies which require relatively labor intensive, time consuming, and expensive molding, machining and drilling, or electroforming operations. Further, it should now be apparent that the use of materials having the above-described characteristics permits the die 110 of the invention to be easily and inexpensively modified to allow for formed articles to be manufactured incorporating various design changes.

In the embodiment shown, the die 110 includes a screen 112 and a plurality of perforations 114 extending inward and through the die 102. These perforations 114 lead through the die 110 as a channel that then connects with the vacuum mechanism 130.

The screen 112 is a fine mesh that provide a smooth upper surface 10A of the body 10, and allows the water to pass through the perforations 114 when sucked by the vacuum mechanism 130. The screen 112 prevents the fiber material from also being sucked through the perforations. The screen 112, the perforations 114, and the vacuum mechanism 130 allow the fiber material to mold to the die 110 surface and then remove enough water from the fiber material to allow the molded fibers to self support itself once it is removed from the die 110.

The die 110 also includes interior filler walls 116, exterior filler walls 118, and a support wall 119. The interior filler walls 116 form the interior filler sections 14, while the exterior filler walls 118 form exterior filler sections 16. In accordance with the description above, the interior filler sections 14 and the exterior filler sections 16 are generally the same thickness, and so do the interior filler walls 116 and the exterior filler walls 118. However, according to the invention, the thickness of the exterior filler sections 16 cannot be larger than the thickness Tg of the interior filler sections 14. If the exterior grout lines 16 are thicker, then the panel member 1 warps. An interior section of the body 10 either bows in or out, which provides a poor appearance and the panel member 1 does not look like a wall or façade prepared from masonry, carpentry, or other finishes. Therefore, the exterior filler walls 118 must have less or equal height than the interior filler walls 116. Furthermore, the exterior filler walls 118 should have a width less than the width of the interior filler walls 116. The upper surface 10 a of the body 10 is formed along the screen 112, and the cavities 20 are formed between the interior filler walls 116.

The support wall 119 is formed on the external wall of the die 110 and determines the height and shape of the flash. Accordingly, the support wall 119 height is limited to the height less than the height of the exterior filler wall 118. The flashing 18, as a result, is limited in height and directed parallel to the upper and lower surfaces 10 a, 10 b of the body 10.

According to the method of producing panel members 1 from a fibrous slurry of the invention, a die 110 comprising a water insoluble, porous (i.e. screen 112 and perforations 114), and relatively rigid and easily shaped material is provided, having a molded surface through a series of walls that replicates a structure prepared from masonry, carpentry, or other finishes. The die 110 is then disposed into a vat having a fibrous slurry. The vacuum mechanism 130, connected to the die 110, draws the fibrous slurry against the screen 112 and molding surface of the die 110 to form a substantially uniform layer of fibrous material. The water is drawn through the perforations 114 in the die 110. The vacuum pressure necessary for drawing the fibrous slurry against the molding surfaces of the forming die may be readily determined by one of ordinary skill in the art and will depend on various process conditions such as the composition and viscosity of the slurry, the temperature of the slurry, and the configuration and wall thickness of the article to be produced.

In one embodiment, when a fibrous layer has been deposited at the desired thickness, the body 10 is formed and the panel member 1 is permitted to dry. After the panel member 1 has dried sufficiently, it may be removed from the die 110 by hand or mechanically with the application of air pressure through the die 110 to push the panel member 1 away from the die 110. In order to reduce drying time, the panel member 1 may be placed into a conventional oven having a temperature of less than about 500 degrees. The amount of time and the particular heating temperature may be readily determined by one of ordinary skill in the art.

Although several embodiments have been shown and described, it would be appreciated by those skilled in the art that various changes or modifications may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents. 

1. A blank, comprising: a body prepared from a substantial uniform caliper of fiber material; a plurality of ornamental sections; a plurality of interior filler sections; and an exterior filler section; wherein a thickness of the exterior filler section is substantially equal to a thickness of the plurality of interior filler sections.
 2. The blank according to claim 1, further comprising a flashing extending from the exterior filler section and directed parallel to a planar upper surface of the wall covering.
 3. The blank according to claim 2, wherein the fiber material is a pulp slurry using pre- and post-consumer paper mixed with water.
 4. The blank according to claim 3, wherein the paper is reduced to small pieces and then further defibered into a homogenized slurry of paper and water, sizing agents, and binders.
 5. The blank according to claim 2, wherein the body comprises a smooth upper surface and a rough lower surface.
 6. The blank according to claim 2, wherein the ornamental sections extend outward from the plurality of interior sections and the exterior filler section.
 7. The blank according to claim 2, wherein the plurality of interior filler sections and the exterior filler section are irregular in shape.
 8. The blank according to claim 2, wherein the plurality of interior filler sections and the exterior filler section are grid shaped having a consistent uniform shape.
 9. The blank according to claim 2, wherein the ornamental sections are hollow with a cavity formed along a lower surface of the body, between the plurality of interior filler sections or the exterior filler section.
 10. The blank according to claim 2, wherein a thickness of the plurality of interior filler sections is substantially equal to a thickness of the ornamental section.
 11. The blank according to claim 2, wherein a thickness of the body equals a combined thickness of the plurality of interior filler sections and the ornamental section thickness.
 12. The blank according to claim 2, wherein a width of the exterior filler section is less than a width of the interior filler section.
 13. The blank according to claim 12, wherein the width of the exterior filler section is half the width of the plurality of interior filler sections.
 14. The blank according to claim 2, further comprising a first connection section positioned on an end of the blank and a second connection section positioned on a side opposite the end having the first connection section.
 15. The blank according to claim 14, wherein the first connection section is keyed to match the second connection section.
 16. The blank according to claim 15, wherein the first and second connection sections complement each other when matched in adjacent connecting blanks.
 17. The blank according to claim 15, wherein the first and second connection sections include finger joints which are complementary polygonal protrusions and cuts outs.
 18. An apparatus for forming blanks from fibrous material, comprising: a die having a molding surface and perforations through molding surface and a body of the die; a molding screen; and a vacuum mechanism positioning fibrous material onto the molding surface and extracting water away from the fibrous material.
 19. The apparatus according to claim 18, wherein the die includes interior filler walls, exterior filler walls, and a support wall.
 20. The apparatus according to claim 18, wherein the interior filler walls form interior filler sections and exterior filler sections of the blank.
 21. The apparatus according to claim 19, wherein the interior filler walls have a greater thickness than the exterior filler walls.
 22. The apparatus according to claim 21, wherein the exterior filler walls height is less or equal in height than the interior filler walls.
 23. The apparatus according to claim 22, wherein the support wall height is less than the height of the exterior filler wall. 